Single joint drilling system

ABSTRACT

A pipe handling system comprising a pipe erector operable to move a pipe from a horizontal storage position to a substantially vertical position wherein an upper end of the pipe is disposed above an elevated drill floor of a drilling rig and the pipe is offset from well center The pipe handling system also comprises an upper vertical support configured to support the pipe in the vertical position independently of said pipe erector

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 60/700,624, filed on Jul. 19, 2005 and titled “Single Joint Drilling System,” which is hereby incorporated by reference herein,

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND

The present invention relates generally to methods and apparatus for drilling wells More specifically, the present invention relates to systems for drilling wells utilizing single joints of pipe

Many smaller drilling rigs store tubular members, such as drill pipe, drill collars, and casing, in horizontal storage areas outside of the rig. As the different tubular members are needed, they are brought to the drill floor one at a time and added to the string. Handling these tubular members has historically been a highly manual job using winches or other lifting appliances within the rig. Automated systems for use in these “single joint” rigs must be able to safely handle a variety of tubular members while not slowing down drilling or tripping processes.

Thus, there remains a need to develop methods and apparatus for pipe handling and drilling systems, which overcome some of the foregoing difficulties while providing more advantageous overall results.

SUMMARY OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention include a pipe handling system comprising a pipe erector operable to move a pipe from a horizontal storage position to a substantially vertical position wherein an upper end of the pipe is disposed above an elevated drill floor of a drilling rig and the pipe is offset from well center The pipe handling system also comprises an upper vertical support configured to support the pipe in the vertical position independently of said pipe erectors

Thus, the embodiments of present invention comprise a combination of features and advantages that enable substantial enhancement of moving pipe and other tubular members to and from a drilling rig. These and various other characteristics and advantages of the present invention will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention and by referring to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:

FIG. 1 is an elevation view of a drilling system designed in accordance with embodiments of the present invention;

FIGS. 2-10 are views of the drilling system of FIG. 1 representing a sequence of events during a drilling or tripping operation;

FIG. 11 is a side elevation view of a pipe erector system constructed in accordance with embodiments of the invention;

FIG. 12 is an end view of the pipe erector system of claim 11 shown in a closed position;

FIG. 13 is an end view of the pipe erector system of claim 11 shown in an open position;

FIG. 14 is a side elevation view of the pipe erector system of claim 11 shown in a first elevated position;

FIG. 14 is a side elevation view of the pipe erector system of claim 11 shown in a second elevated position;

FIG. 16 is a top view of an upper vertical pipe support constructed in accordance with embodiments of the invention;

FIG. 17 is a side view of the upper vertical pipe support of FIG. 16;

FIG. 18 is a front view of the upper vertical pipe support of FIG. 16 shown in a closed position;

FIG. 19 is a side view of the upper vertical pipe support of FIG. 16 shown in an open position;

FIG. 20 is a side view of the upper vertical pipe support of FIG. 16 shown engaged with a pipe member;

FIGS. 21 and 22 shown drill floor equipment constructed in accordance with embodiments of the invention;

FIGS. 23A-F illustrate the loading of pipe from a pipe handling system constructed in accordance with embodiments of the invention;

FIGS. 24A-F illustrate the loading of pipe onto the pipe handling system of FIGS. 23A-F.

FIGS. 25A-H illustrate the loading of pipe from a pipe handling system constructed in accordance with embodiments of the invention;

FIGS. 26A-H illustrate the loading of pipe onto the pipe handling system of FIGS. 25A-H;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 1, drilling system 10 comprises rig structure 12, hoisting system 14, pipe erecting system 16, top drive system 18, and drill floor equipment 20. Rig structure 12 comprises mast 22, drill floor 24, and sub-structure 26. Hoisting system 14 comprises drawworks 28, crown block 30, and traveling block 32. Top drive system 18 comprises top drive 34, bails 36, and elevator 38. Pipe handling system 16 comprises erector 40, horizontal supports 42, lower vertical support 44, and upper vertical support 46. Drill floor equipment 20 comprises iron roughneck system 48 and slips 50 that are located on well center 52.

FIGS. 2-10 illustrate the procedure used for drilling or running pipe into the hole. In FIG. 2, top drive 34 is fully lowered toward drill floor 24 and a joint of pipe 54 needs to be added to the drill string 56. Erector 40 has raised pipe 54 to a substantially vertical position that is offset from well center 52 and an upper end of the pipe is above drill floor 24. Vertical supports 44 and 46 secure pipe 54 in the substantially vertical position so that erector 40 can be disengaged and pivoted back to horizontal, as shown in FIG. 3.

To add pipe 54 to drill string 56, the drill string is first secured to drill floor 24 by slips 50 Once secured, top drive 34 can be detached from drill string 26 and raised, as shown in FIG. 4. Once clear of the top of drill string 56, elevator 38 and bails 34 are rotated to an extended position where the elevator is aligned with the offset position of pipe 54. Elevator then engages pipe 54, as shown in FIG. 5.

Referring now to FIGS. 6 and 7, top drive 34 is raised toward the top of mast 22, carrying pipe 54 supported by elevator 38. Elevator 38 maintains pipe 54 in the position offset from well center 52 until the lower end of the pipe clears upper vertical support 44 and the upper end of drill string 56. Once raised, elevator 38 is rotated back to its initial position so that pipe 54 is substantially on well center 52.

As shown in FIG. 8, once pipe 54 is aligned with well center 52, top drive 34 is lowered and pipe 54 engaged with drill string 56. The engagement of pipe 54 with drill string 56 may be enabled by a stabbing system (not shown) or manual intervention. As illustrated in FIG. 9, once pipe 54 is engaged with drill string 56, roughneck system 48 is moved to well center 52 and makes-up the connection between pipe 54 and drill string 56. Top drive 34 can then engage the upper connection of pipe 54 and continue drilling or running the drill string into the well, as is shown in FIG. 10. When top drive 34 nears drill floor 24, the process repeats and another pipe joint is added to the drill string. It is understood that, during tripping and other operations, top drive 34 does not engage drill string 56 and the drill string is supported solely by elevator 38. Drill string is removed from the well by reversing the above procedure and using erector 40 to move pipe 54 back to a horizontal position.

Pipe handling system 16 comprises pipe erector 40 that moves a single joint of pipe at a time from a substantially horizontal storage position to a substantially vertical position where an upper end of the pipe is above an elevated drill floor and the pipe is offset from well center. It is understood that when in either the storage position or the substantially vertical position, the pipe is not required to be exactly horizontal or vertical and that some deviation from these orientations may be possible.

Referring now to FIGS. 11-13, erector 40 engages pipe 54 that has been disposed on horizontal supports 42 by a pipe handling system or other means. Erector 40 comprises two pairs of capture arms 56 mounted to frame 58, which is connected to base 60 at pivot 62. Frame 58 also comprises ledge 64. Hydraulic cylinder 66 is coupled to frame 58 and base 60. Hydraulic cylinder 68 is coupled to capture arm 56 and base 60.

Erector 40 is in a horizontal position with capture arms open, as shown in FIG. 13, as pipe 54 is placed on horizontal supports 52 Hydraulic cylinder 68 is extended so that capture arms 56 rotate to a closed position, as shown in FIG. 12. Once capture arms 56 are closed, hydraulic cylinder 66 is retracted, rotating erector 40 about pivot 62 from horizontal to the vertical position shown in FIG. 14. As erector 40 rotates, pipe 54 comes to rest on, and be vertically supported by ledge 64. Once pipe 54 is vertical, lower vertical support 44 lifts the pipe off of ledge 64, as shown in FIG. 15. Lower vertical support 44 lifts pipe 54 by raising platform 70 via hydraulic cylinder 72 to engage and lift the bottom of the pipe. In certain embodiments, ledge 64 is moveable relative to erector 40 and is used to lift pipe 54 onto lower vertical support 44 (which is stationary) and also to adjust the axial position of the pipe with the erector is in the horizontal position. Once, pipe 54 is lifted so that ledge 64 clears the bottom of the pipe, erector 40 is rotated back to the horizontal position.

Referring back to FIG. 1, when pipe 54 is vertical it is also supported by upper vertical support 46, which captures the pipe at or near drill floor 24 On-e embodiment of an upper vertical support 46 is shown in FIGS. 16-20. FIG. 16 shows a top down view of upper vertical support 46 comprising swing aims 74, hinge members 76, actuation cylinder 78, and linkages 80. FIG. 17 is a side view of upper vertical support 46. The operation of upper vertical support 46 is shown in FIGS. 18-20, which show a front view of the support. FIG. 18 shows swing arms 74 in a filly closed position and actuation cylinder 78 in an extended position. Linkage 80 couples cylinder 78 to swing arms 74. Referring now to FIG. 19, as cylinder 48 is moved to a retracted position, linkage 80 moves downward and causes swing arms 74 to rotate outward about hinge members 76 and allow pipe 82 to pass between the swing arms. Cylinder 48 is then moved back toward the extended position, which causes swing arms 74 to rotate inward and engaged pipe 82, as shown in FIG. 20.

Referring back to FIG. 1, drill floor equipment 20, comprising iron roughneck system 48 and slips 50, is used to make and break pipe connections as pipe joints are added to, or removed from, the drill string The operation of drill floor equipment 20 is further shown in FIGS. 21 and 22 Iron roughneck system 48 comprises torque wrench 84 and spinner 86 mounted to swinging frame 88 and stabbing guide 90 mounted to mast 22. Swinging frame 88 forms a parallelogram-shaped support structure that allows rough-neck system 48 to be moved to and from well center as needed In certain embodiments, iron roughneck system 48 may be removed from swinging frame 88 and replaced with casing tongs or other equipment for handling specific tubular members. Alternatively, swinging frame 88 may allow for iron roughneck system 48 to be rotated to an elevated or other position that allows for the use of casing tongs or other equipment for handling specialized tubular members.

As pipe joint 92 is lowered, stabbing guide 90 aligns the pipe joint with drill string 94, which is supported by slips 50. As pipe joint 92 engages drill string 94, swinging frame 88 moves torque wrench 84 and spinner 86 toward the well center, as shown in FIG. 22. Spinner 86 engages pipe joint 92 and rotates the pipe so as to engage the threaded connection to drill string 94 Torque wrench 84 then applies the necessary torque to the threaded connection to secure the connection. When removing pipe joints from the drill string torque wrench 84 applies torque to break the connection and spinner 86 rotates the pipe joint to disengage the treaded connection

As described above, drilling system 10 and pipe erecting system 16 operates by taking pipe from a horizontal orientation and placing the pipe back in the horizontal orientation after use. Once horizontal, the pipe can be handled by a number of different pipe handling systems and methods. In certain embodiments, automated systems can be used to handle horizontal pipe without direct involvement of personnel. One such pipe handling system is illustrated in FIGS. 23A-F and 24A-F.

Referring now to FIG. 23A, pipe handling system 100 comprises rack 102, frame 104, tilting mechanism 106, elevated stop 108, and pipe unloading assembly 110. Unloading assembly 110 comprises lifting block 114 and rotating arm 116. When loading pipes 112 onto erector 40, tilting mechanism 106 raises the end of rack 102 so as to angle the rack toward erector 40. The movement of pipes 112 along rack 102 is limited by elevated stop 108.

Referring now to FIGS. 23B-23F, to load a single joint of pipe 112 onto erector 40, lifting block 114 is raised, pushing a single joint of pipe 112 upward The pipe 112 moves over and past elevated stop 108 toward the end of rack 102. Lifting block 114 is then lowered so that the remainder of pipes 118 can move downward until contacting elevated stop 108. At the end of rack 102, pipe 112 is stopped by arm 116, which is disposed in a raised position. Ann 116 is then rotated to lower pipe 112 onto erector 40. Arm 116 continues rotating downward so that is out of the way of erector 40. Erector 40 can then lift pipe 112 upward and away from pipe handling system 100.

FIGS. 24A-F illustrate pipe handling system 100 being used to store pipes being removed from a drill string. When moving pipes 112 from erector 40, tilting mechanism 106 lowers the end of rack 102 so as to angle the rack away from erector 40. Lifting block 114 and elevated stop 108 are retracted into rack 102 so as to provide a smooth surface along which pipe 112 can roll. Once pipe 112 is lowered and released by erector 40, arm 116 rotates upward so as to lift the pipe from the erector. Arm 116 continues to rotate until pipe 112 falls onto rack 102 where it will roll toward the far end of the rack.

Another pipe handling system is shown in FIGS. 25A-H and 26A-H. Pipe handling system 200 comprises frame 202 that is pivotally mounted on base 204. The incline of frame 202 is controlled by piston 206. The loading and unloading of pipe into handling system 200 is done by pipe moving assembly 210. Pipe moving assembly 210 comprises extendable finger 214, rotatable arm 216, and drive motor 218. Assembly 210 is slidably mounted to a vertical member of frame 202 so that drive motor 218 engages gear rack 220.

The unloading of pipe from handling system 200 is illustrated in FIGS. 25A-H. Piston 206 inclines frame 202 so that pipe joints 212 tend to move toward pipe moving assembly 210. Finger 214 extends to separate a single joint of pipe from the row of pipes stored in frame 202. Assembly 210 the moves upward until pipe 212 clears frame 202, as shown in FIG. 25B. Pipe 212 will roll down assembly 210 until it contacts arm 216, which is in an levated position. With pipe 212 resting against arm 216, assembly 210 moves downward along flame 202 to the position shown in FIG. 25D. Arm 216 then rotates so as to lower pipe 212 into erector 40 and continues rotating until reaching a lowered position as shown in FIG. 25E. With arm 216 in a lowered position, erector 40 can capture pipe 212 and move the pipe to the drill floor. Once erector 40 has moved out of the way, assembly 210 is moved back to uppermost row of pipes and arm 216 is rotated back to the elevated position

The loading of pipe from erector 40 back into handling system 200 is illustrated in FIGS. 26A-H. Piston 206 inclines frame 202 so that pipe joints 212 tend to move away from moving assembly 210A Mover assembly 210 is disposed adjacent to erector 40, once erector 40 lowers pipe 212 to a horizontal position. Once erector 40 disengages pipe 212, arm 216 rotates to lift pipe 212 from erector 40. Mover assembly 210 then moves up frame 202 until pipe 212 clears the top of the frame. Once inside frame 202, pipe 212 is restrained by extended finger 214 and bumper 215. Mover assembly 210 moves back down frame 202 until pipe 212 is at the row of pipe being loaded Finger 214 then retracts and pipe 212 will roll into position within frame 202. Mover assembly 210 is then moved back to the proper elevation to receive pipe from erector 40 and arm 216 is rotated back to its lowered position.

Referring now to FIGS. 27 and 28, an alternate pipe erecting system 300 comprises erector system 302 that moves a single joint of pipe at a time from a horizontal position to a vertical position where the pipe is restrained by vertical support system 304. Erector system 302 further comprises erector frame 306, capture arms 308, pivot 310, elevating cylinder 312, base frame 314, support finger 316, and finger cylinder 318 Vertical support system 304 comprises frame 320, pipe rest 322, lower funnel guide 324, and upper funnel guide 326.

Referring to FIG. 27, erector 302 is in a horizontal position. Capture arms 308 secure pipe 54 to erector 302. Once capture arms 308 are closed, elevating cylinder 312 operates to rotate erector 302 about pivot 310 from horizontal to the vertical position shown in FIG. 28. As erector 302 rotates, pipe 54 comes to rest on, and be vertically supported by finger 316. Once pipe 54 is vertical, finger cylinder 318 lowers finger 316 so that the pipe come to rest on pipe rest 322. Referring to FIG. 28, when pipe 54 is vertical it is also supported by upper funnel guide 324 and lower funnel guide 326. Funnel guides 324 and 326 may be similar to vertical support 46 of FIGS. 17-20. Once pipe 54 is fully supported by vertical support system 304, capture arms 308 can be opened and erector 302 can then be rotated back to the horizontal position of FIG. 27.

FIGS. 29-32 illustrate a pipe erector system 400 that incorporates a system for handling and installing blowout preventer 402. Pipe erector system 400 comprises base 404, erector arm 406, vertical support arm 408, and blowout preventer handling arm 410. FIG. 29 shows pipe erector system 400 in a transport configuration emplaced adjacent to wellhead 412. Pipe erector system 400 is preferably configured so as to be transported with blowout preventer 402 via standard road trailers

Erector arm 406 is pivotally coupled to base 404 at pivot 414. Pin connection 418 couples handling arm 410 to support arm 408, which is pivotally coupled to base 404 at pin connection 416. When in the transport configuration of FIG. 29, erector arm 406, support arm 408, and handling arm 410 are in a horizontal position. Once pipe erector system 400 is emplaced adjacent to wellhead 412, erector arm 406, support arm 408, and handling arm 410 are pivoted about pivot 414 to an elevated, substantially vertical position as shown in FIG. 30. Arms 406, 408, and 410 may be pivoted by the hydraulic cylinder (not shown) that is used to operate erector arm 406 during normal operations.

Once elevated to the vertical position, erector arm 406 can be disconnected from support arm 408 and returned to its horizontal position as shown in FIG. 31. Handling arm 410 is then tilted outward from support arm 408 by extending actuator 420 and pivoting the handling arm about pin connection 418 Handling arm 410 is tilted outward until blowout preventer 402 is aligned with wellhead 412,

Lifting frame 422 and cable 424, which travels over pulley 426 and is coupled to actuator 428, supports blowout preventer 402. Blowout preventer 402 is lowered by extending actuator 428 until the blowout preventer is supported by wellhead 412, as is shown in FIG. 31. Once blowout preventer 402 is set on wellhead 412, lifting frame 422 is disconnected from the blowout preventer and handling arm 410 is tilted back to vertical as shown in FIG. 32. Once handling arm 410 is secured, pipe erector system 400 is ready for operation.

While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. 

1. A pipe handling system comprising: a pipe erector operable to move a pipe from a horizontal storage position to a substantially vertical position wherein an upper end of the pipe is disposed above an elevated drill floor of a drilling rig and the pipe is offset from well center; and an upper vertical support configured to support the pipe in the vertical position independently of said pipe erector.
 2. The pipe handling system of claim 1, further comprising a lower vertical support coupled to said pipe erector and configured to control the elevation of the pipe in the vertical position.
 3. The pipe handling system of claim 1, wherein said upper vertical support comprises a pair of swing arms that are rotatable between an open position wherein the pipe call pass between said swing arms and a closed position where the pipe is engaged by both swing arms.
 4. The pipe handling system of claim 1, further comprising a pair of capture arms coupled to said pipe erector, wherein said capture arms are rotatable between an open position that allows the pipe to be moved onto or off of said erector and a closed position wherein said capture arms secure the pipe to said erector.
 5. The pipe handling system of claim 1, further comprising a ledge coupled to said pipe erector, wherein said ledge limits the axial movement of the pipe being supported by said pipe erector.
 6. The pipe handling system of claim 1, further comprising: a base pivotally coupled to said pipe erector; and an actuator coupled to said base and said pipe erector, wherein said actuator is configured to move said pipe erector from a horizontal position to a vertical position.
 7. The pipe handling system of claim 6 wherein said upper vertical support is coupled to said base.
 8. The pipe handling system of claim 6 further comprising a blowout preventer handling arm coupled to said base.
 9. A drilling system comprising: a drilling rig having an elevated drill floor; a pipe erector operable to move a pipe from a horizontal storage position to a substantially vertical position wherein an upper end of the pipe is disposed above the elevated drill floor and the pipe is offset from well center; and an upper vertical support configured to support the pipe in the vertical position independently of said pipe erector.
 10. The drilling system of claim 9, further comprising a lower vertical support coupled to said pipe erector and configured to control the elevation of the pipe in the vertical position.
 11. The drilling system of claim 9, wherein said upper vertical support comprises a pair of swing arms that are rotatable between an open position wherein the pipe can pass between said swing aims and a closed position where the pipe is engaged by both swing arms.
 12. The drilling system of claim 1, further comprising a pair of capture arms coupled to said pipe erector, wherein said capture arms are rotatable between an open position that allows the pipe to be moved onto or off of said erector and a closed position wherein said capture arms secure the pipe to said erector.
 13. The drilling system of claim 1, further comprising a ledge coupled to said pipe erector, wherein said ledge limits the axial movement of the pipe being supported by said pipe erector.
 14. The drilling system of claim 1, further comprising: a base pivotally coupled to said pipe erector; and an actuator coupled to said base and said pipe erector, wherein said actuator is configured to move said pipe erector from a horizontal position to a vertical position.
 15. The drilling system of claim 14 wherein said upper vertical support is coupled to said base
 16. The drilling system of claim 14 further comprising a blowout preventer handling arm coupled to said base.
 17. A method for operating a drilling rig comprising: loading a pipe onto a pipe erector disposed in a horizontal position; moving the pipe erector to an elevated position wherein the pipe is in a substantially vertical position where an upper end of the pipe is disposed above an elevated drill floor of a drilling rig and the pipe is offset from well center; engaging the pipe with an upper vertical support that maintains the substantially vertical position of the pipe; disengaging the pipe from the pipe erector; and moving the pipe erector to the horizontal position.
 18. The method of claim 17 wherein the pipe is disengaged from the pipe erector by operating a lower vertical support to lift the pipe from a ledge disposed on the pipe erector and moving a pair of capture arms to an open position so that the pipe can be disengaged from the pipe erector.
 19. The method of claim 17 further comprising: engaging the upper end of the pipe with an elevator supported by the drilling rig; releasing the pipe from the upper vertical support; lifting the pipe above the elevated drill floor; and moving the pipe to well center.
 20. The method of claim 19 further comprising: connecting the pipe to a drillstring supported at the drill floor; loading a second pipe onto the pipe erector disposed in the horizontal position; moving the pipe erector to the elevated position; engaging the second pipe with the upper vertical support; disengaging the second pipe from the pipe erector; and moving the pipe erector to the horizontal position. 